GE Oil & Gas
Aeroderivative Gas Turbine
Emission Reduction
Techniques
DLE1.0 system
Imagination at work.
Emission Reduction Techniques
Why?
Low environmental impacts
Local Government restrictions
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Gas Turbine Emissions
Gas Turbine Emissions
Typical concentration
Major species Source
(% volume)
Nitrogen (N2) 66-72 Inlet air
Oxygen (O2) 12-18 Inlet air
Carbon dioxide (CO2) 12-18 Oxidation of fuel carbon
Water vapor (H2O) 12-18 Oxidation of fuel hydrogen
Typical concentration
Minor species pollutants Source
(PPMV)
Nitric oxide (NO) 20-220 Oxidation of atmosphere nitrogen
Nitrogen dioxide (NO2) 2-20 Oxidation of fuel bound organic nitrogen
Carbon monoxide (CO) 5-330 Incomplete oxidation of fuel carbon
Sulfur dioxide (SO2) Trace-100 Oxidation of fuel bound organic solfur
Sulfur trioxide (SO3) Trace-4 Oxidation of fuel bound organic solfur
Unburned hydrocarbons (UHC) 5-300 Incomplete oxidation of fuel or intermediates
Particulate matter smoke Trace-25 Inlet ingestion, fuel ash, hot gas path
attrition, incomplete oxidation of fuel
or intermediates
Gas turbine emissions burning conventional fuels
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Gas Turbine Emissions
Characteristics of Conventional Combustion Systems
NOx (ppmvd/ppmvw-methane)
Stoichiometric flame
Fuel 1765°F/963°C-2020°F/1104°C
temperature
Firing temperature
Methanol 0.417-0.617 0.489/0.501
increasing Methane 1.000 1.000/1.000 Increasing
flame NOx
temperature Butane 1.280 1.608/1.661 emissions
values
Propane 1.300 1.555/1.606
No. 2 oil 1.667 1.567/1.647
Hydrogen 2.067 3.966/4.029
Carbon Monoxide 2.067 3.835/3.928
The higher the flame temperature,
the greater the NOx emission is.
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Gas Turbine Emissions
Equivalence Ratio
The equivalence ratio is defined as:
Ga /Gf α
λ= = λ < 1 means excess of fuel (rich mixture)
αs αs
where: λ > 1 means excess of air (lean mixture)
• Ga is the air mass flow
• Gf is the fuel mass flow
• 𝛼𝛼 is the actual air-to-fuel ratio, (Ga /Gf )
• 𝛼𝛼s is the stoichiometric air-to-fuel ratio, i.e. represents a mixture where
theoretically all the oxygen in the air reacts with the fuel
Methane (CH4 ): 𝛼𝛼s = 17.23
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Gas Turbine Emissions
Equivalence Ratio
Away from the stoichiometric
flame, the formation of NOx
quickly decreases.
(excess of fuel) Stoichiometric (excess of air)
conditions
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Gas Turbine Emissions
CO & NOx emissions typical trends
Desired
Desired Operating
CO & NOx Operating Range
Emissions Range 100 25
(λ≈1,7)
NOx 80 20
CO NOx
emissions emissions
(ppmv) 60 15 (ppmv)
NOx
40 CO 10
20 5
CO
1100 1200 1300 1400 1500 1600 1700
Flame Temperature (°C)
1,2 1,3 1,4 1,5 1,6 1,7 1,8 CO and NOx emissions can be both
Equivalence Ratio (λ) minimized, but only in a narrow flame
Rich Lean
temperature range.
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Gas Turbine Emissions
Standard vs. DLN combustion systems
Standard Diffusion Combustor: A/F Poorly Mixed
Max Temp. Dry
Flame Temp
NOx
Lean A/F Lean A/F
Rich A/F Rich A/F Rich A/F
Lean A/F Lean A/F
Rich A/F Dry Wet
Wet
A/F Flame Temp
DLE Combustor: A/F Premixed
Flame Temp
NOx
Max Temp.
Mixing Zone – Lean A/F
No Reaction Mixture
A/F Flame Temp
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Gas Turbine Emissions
Diffusive flame vs. premixed flame
Diffusion Combustion System Premixed Combustion System
Fuel and air are injected separately in the Fuel and air are mixed before being injected
combustion chambers in the combustion chambers
The flame of a candle is a classic example of The flame of a welding torch is a classic
a diffusive flame. example of a premixed flame.
Candle Blowtorch
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Gas Turbine Emissions
Diffusive flame vs. premixed flame
Diffusion Combustion System Premixed Combustion System
ADVANTAGES ADVANTAGES
Stable behaviour within a large range of Possibility to manage the air-to-fuel
equivalence ratio (λ) values equivalence ratio (λ) in the combustors
Simple combustion control system Low NOx emissions
DRAWBACKS DRAWBACKS
Difficulties to limit the flame temperature Combustion stable and efficient only in a
and thus to control NOx emissions narrow range of air-to-fuel ratios
Pressure oscillations in the combustion
chambers may occur
More complex combustion and control
systems are needed
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DLE Combustion System Hardware
DLE Combustion System Hardware
Overview
LM2500/LM2500+ DLE combustion system
features a lean premixer combustion system
designed to operate with natural gas fuel
Features
Number of chambers 1
Comb. Chamber type annular flow
Total number of fuel injectors 75
Max Firing Temperature > 1200 °C
NOx Emissions ≤ 25 ppmv @15%O2
(75% ÷ 100% load)
Materials
Combustor liner Hastelloy X & Haynes 188
material (cobalt-base superalloy)
protected from high combustion
heat by circumferencial film-cooling
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DLE Combustion System Hardware
SAC Vs. DLE
Single Annular Combustor Emission Control Technology
Water Injection
25ppmv NOx (gas fuel)
42ppmv NOx (liquid fuel)
Steam Injection
25ppmv NOx (gas fuel)
Dry Low Emissions (DLE) Combustor
15ppmv NOx (gas fuel) under development
25ppmv NOx (gas fuel)
100ppmv NOx (liquid fuel)
Triple Annular Combustor
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DLE Combustion System Hardware
Compressor Rear Frame (PGT25/PGT25+ DLE)
The Compressor Rear Frame supports:
B sump, Hub and outer casing
(the latter held in position by 10 struts)
1st stg HPT nozzle
combustion chamber and fuel premixers
Compressor Rear Frame is
made of Inconel 718
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DLE Combustion System Hardware
Compressor Rear Frame
CRF STRUT POSITIONS
VIEW FROM AFT
LOOKING FORWARD
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DLE Combustion System Hardware
Triple Annular Combustor
The triple annular design allows the combustor to
operate in uniformly premixed, lean air-to-fuel ratio
throughout the entire power range, minimizing
emissions even at partial loads.
compressor
discharge
diffuser
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DLE Combustion System Hardware
Triple Annular Combustor
Outer ring (A) 30 cups Pilot ring (B) 30 cups Inner ring (C) 15 cups
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DLE Combustion System Hardware
DLE Fuel Manifold
Gas fuel is introduced into the combustor via 75 air/gas premixers packaged in 30 externally
removable and field replaceable modules.
Half of the modules have two premixers and the other half have three premixers.
A three ring tubular manifold supplies gas fuel to the premixers via flexible fuel hoses.
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DLE Combustion System Hardware
DLE Fuel Premixers
High outlet speeds
avoid flashback
Fuel
Air
> 90 m/s
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DLE Combustion System Hardware
DLE Fuel Premixers
Shroud
The premixer produces an
homogeneous lean
Swirler fuel/air mixture
Axial counter-rotating swirlers
enhance fuel/air mixing
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DLE Combustion System Hardware
ELBO Fuel
The system operation is also
enhanced using a lean blow-out
(ELBO) circuit.
ELBO fuel is diffusively burnt to
stabilize the flame
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DLE Combustion System Hardware
Heat Shields
After looking forward
Heat shields
forms three
burning rings
Separating
fins
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DLE Combustion System Hardware
Combustor Domes
The premixers are supported by
proper structure, which is cooled
by compressor discharge air
Forward looking after
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DLE-1.0 Combustion System Operation
DLE-1.0 Combustion System Operation
DLE Combustor Staging
As the need for fuel increases,
more combustor rings are fired,
increasing the firing temperature
while ensuring that proper flame
conditions are locally met.
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DLE-1.0 Combustion System Operation
DLE Combustor Operating Modes
2. B + C/2 Mode
39 premixers
1. B Mode Idle to 5% load
30 premixers
Start to Idle 3. B + C Mode
45 premixers
5 ÷ 25% load
4. A + B Mode 5. A + B + C Mode
60 premixers 75 premixers
25 ÷ 50% load 50 ÷ 100% load
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DLE-1.0 Combustion System Operation
Fuel Staging Valves
DLE-1.0 system installs
11 fuel staging valves
(mounted on the gas
manifold) to properly
control fuel distribution
to the three
combustion domes
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DLE-1.0 Combustion System Operation
DLE Fuel System Configuration
2 shut-off valves
3 fuel metering valves
11 staging valves
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DLE-1.0 Combustion System Operation
Gas Fuel System
Ring B (pilot) has 1 staging
valve that feeds the pilot
fuel of 15 cups (ELBO)
Ring C has 5 staging valves
Ring A has 5 staging valves
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DLE-1.0 Combustion System Operation
Bulk Flame Temperature
Bulk Flame Temperature is the average flame temperature in the domes that are supposed to be burning
(active domes).
It is a calculated parameter (not measured), starting from:
Airflow in the active domes (calculated from HP turbine flow and assumed airflow distribution in the
combustor)
Total fuel flow
TFLAME ≈ T3 * LHV * (Gfuel/Gair)
The bulk flame temperature is expected to be always within the following two limits:
TFLMAX: is the max allowable average flame temperature: operating the gas turbine above this value can
result in excessive NOx emissions and/or extensive damage to the combustor.
TFLMIN: is the min allowable average flame temperature: operating the gas turbine below this value can
lead to flame blowouts.
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DLE-1.0 Combustion System Operation
Bulk Flame Temperature
DLE operation
is not possible
in this range!
The operating power range for
each combustor configuration
is limited within the min and
max bulk flame temperatures
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DLE-1.0 Combustion System Operation
DLE Combustor Operating Modes
A+B+C
COMBUSTOR EXIT TEMPERATURE
A+B
B+C
Bleeding some compressor
B+C/2 air, it becomes possible to fill
the ‘gaps’ between the DLE
combustor operating modes
B
POWER
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DLE-1.0 Combustion System Operation
DLE Combustor Operating Window
Max Bulk Flame Temperature /
Fuel Flow Limit “staging up”
transition point
Max Bleed
Increasing Tflame
Decreasing Bleed
Zero Bleed
“staging down”
transition point
Min Bulk Flame Temperature /
Fuel Flow Limit As power increases, the Control
System adjusts the bleed valve
position in order to maintain the bulk
flame temperature within the limits
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DLE-1.0 Combustion System Operation
DLE Compressor Bleed
Compressor discharge air
is bled through CRF struts
and one bleed valve
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DLE-1.0 Combustion System Operation
DLE Combustor Operating Modes
A+B+C
COMBUSTOR EXIT TEMPERATURE
A+B
B+C
B+C/2
POWER
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DLE-1.0 Combustion System Operation
Ring Flame Temperature
Ring (or “Dome”) Flame Temperatures are the temperature of hot gases in the specific domes.
Both A and C ring flame temperatures are calculated (not measured), starting from:
Airflow in the individual dome
Fuel flow delivered to individual dome
T3
Lower heating value (LHV)
The flame temperatures in the A and C rings are independently controlled to avoid high dynamic pressure
(combustor acoustics).
While the bulk flame temperature is controlled to stay within the lower and upper limits, A and C ring flame
temperatures are scheduled as a function of T3 and combustor configuration.
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DLE-1.0 Combustion System Operation
Ring Flame Temperature Distribution: Piston Analogy
B
A B C
A C
Bulk Flame
Temp
Same Bulk Temperature
A & C colder - B hotter Uniform Distribution
Having fixed the bulk flame temperature,
unlimited combinations of ring flame
temperature distributions are available
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DLE-1.0 Combustion System Operation
Ring Flame Temperature
TFLMAX
TFLMAX: max bulk flame temperature limit
TFLMIN: min bulk flame temperature limit
TFL INNER: C ring flame temperature schedule
TFLMIN
TFL OUTER: A ring flame temperature schedule
TFLMAX
TFLMAX
TFLMIN
TFLMIN
TFL INNER
TFL INNER
April 15 GE Proprietary Information | All Rights Reserved Page 39
DLE-1.0 Combustion System Operation
Ring Flame Temperature
TFLMAX
TFLMIN
TFL OUTER
TFL INNER
TFLMAX
TFLMIN
TFL OUTER
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DLE-1.0 Combustion System Operation
Combustor Acoustics (Dynamic Pressure Fluctuation)
Interaction of unsteady heat release with the acoustic of the
system is a self-sustaining mechanism
Heat release
Flow and mixture perturbation Pressure dynamics
If pressure and heat release are in favorable phase relation, a self
amplification of the oscillation occurs
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DLE-1.0 Combustion System Operation
Acoustic Baffles (Elk horns)
Acoustic baffles dump pressure
dynamics inside the combustor
Baffles have different shape and
dimension to attenuate all the
acoustic frequencies
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DLE-1.0 Combustion System Operation
Acoustic and Blowout Avoidance (ABAL) System
Why is Acoustic and Blowout Avoidance (ABAL) system required?
• the margin between a blowout and acoustics condition is often small
• acoustics or blowout boundaries drift with time
• it is not desirable to have to constantly remap engines
ABAL automatically lowers or raises A or C ring temperatures (or bulk flame temperature
when in B mode) when high combustor acoustics or partial blowouts are detected.
ABAL can also reduce the high combustor acoustics or partial blowouts that are common
when transitioning to a new combustor mode.
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DLE-1.0 Combustion System Operation
Acoustic and Blowout Avoidance (ABAL) System
Two sensors, mounted on the compressor rear
frame, measure the combustor acoustics as a
dynamic pressure level (peak-to-peak psi).
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DLE-1.0 Combustion System Operation
Acoustic and Blowout Avoidance (ABAL) System
TFLMAX
Adjustment ABAL corrective action for high acoustics or partial blowouts
Acoustic
Sensors
TFLMIN B mode
Adjustment TFLMAX and TFLMIN decreased for high acoustics
ABAL TFLMAX and TFLMIN increased for partial blowouts
System TFL INNER
BC/2 and BC mode
Adjustment
Logic TFL INNER (C ring) reference decreased for high acoustics
TFL INNER (C ring) reference increased for partial blowouts
TFL OUTER
Blowout
Adjustment
Detection AB mode
Logic TFL OUTER (A ring) reference decreased for high acoustics
TFL OUTER (A ring) reference increased for partial blowouts
ABC mode
Partial blowouts are not so easy to detect TFL OUTER, then TFL INNER reference decreased for high acoustics
and certainly can’t be directly measured TFL OUTER, then TFL INNER reference increased for partial blowouts
A model-based blowout detection (BOD)
algorithm is used.
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Thank you.
Questions & Answers
46
Introduction & General Overview
April 15 GE Proprietary Information | All Rights Reserved maggio 2013 46
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